The customer makes spacers for torque converters made from 1045 using a CNC lathe IKEGAI-Fx 25N with external coolant.
Tool used: Kennametal special diameter IC drill
- Hole diameter = 1.9" (48.3mm)
- Hole depth = 3” (76.2mm)
- 500 RPM
- 0.003 IPR (0.08 mm/rev)
- 1.5 IPM (38.1 mm/min)
- Cycle time = 120 seconds
- Tool life = 300 holes
Because the Kennametal tool was expensive and had lengthy lead times, the customer asked Allied for a solution that would also improve cycle times and lower the cost per hole.
Allied recommended the Revolution Drill.
Tool used: Revolution Drill holder (R34X22-150L) and insert (item OP-05T308-H)
- 900 RPM
- 0.0035 IPR (0.09 mm/rev)
- 3.15 IPM (80 mm/min)
- Cycle time = 60 seconds
- Tool life = 600 holes
The Revolution Drill met the customer's needs and provided twice as many drilled holes in half the time.
- Doubled the tool life
- Cut the cycle time in half
- Reduced cost per hole from $2.14 to $0.98
- Total cost savings = 54.38%